US12359224B2 - Integrated gas fermentation and carbon black processes - Google Patents

Integrated gas fermentation and carbon black processes

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US12359224B2
US12359224B2 US18/674,430 US202418674430A US12359224B2 US 12359224 B2 US12359224 B2 US 12359224B2 US 202418674430 A US202418674430 A US 202418674430A US 12359224 B2 US12359224 B2 US 12359224B2
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gas
fermentation
carbon black
downstream operation
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US20240401086A1 (en
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Jennifer Rosa Holmgren
Steven Tadashi Arakawa
Sean Alex Rollag
Richard Russell Rosin
Taylor Craig Schulz
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Lanzatech Inc
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Lanzatech Inc
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Assigned to LANZATECH, INC. reassignment LANZATECH, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HOLMGREN, JENNIFER ROSA, ROLLAG, Sean Alex, ROSIN, RICHARD RUSSELL, SCHULZ, Taylor Craig, ARAKAWA, STEVEN TADASHI
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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P3/00—Preparation of elements or inorganic compounds except carbon dioxide
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N1/00—Microorganisms; Compositions thereof; Processes of propagating, maintaining or preserving microorganisms or compositions thereof; Processes of preparing or isolating a composition containing a microorganism; Culture media therefor
    • C12N1/20—Bacteria; Culture media therefor
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N1/00—Microorganisms; Compositions thereof; Processes of propagating, maintaining or preserving microorganisms or compositions thereof; Processes of preparing or isolating a composition containing a microorganism; Culture media therefor
    • C12N1/32—Processes using, or culture media containing, lower alkanols, i.e. C1 to C6
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • C12P7/065—Ethanol, i.e. non-beverage with microorganisms other than yeasts
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/40—Preparation of oxygen-containing organic compounds containing a carboxyl group including Peroxycarboxylic acids
    • C12P7/54—Acetic acid

Definitions

  • the process further comprising passing at least a portion of the second secondary product stream to the gas fermentation process.
  • the first secondary product stream further comprises sulfur or a sulfur containing component
  • the process further comprising separating a first sulfur or a sulfur containing component stream from the first secondary product stream and providing the first sulfur or a sulfur containing component stream to the downstream operation.
  • the downstream operation to produce an article of manufacture is at least one step of a tire production process.
  • two or more byproducts are produced by the partial oxidation, pyrolysis, torrefaction, reforming, or gasification process and the two or more byproducts are provided to the same or different steps of a production process to manufacture a tire.
  • the at least one material comprises a natural or synthetic rubber containing material.
  • a second sulfur or sulfur component containing stream is separated from the at least one secondary product stream and provided to the downstream operation to produce an article of manufacture.
  • two or more byproducts are produced by the partial oxidation, pyrolysis, torrefaction, reforming, or gasification process and the two or more byproducts are provided to the same or different steps of the production process to manufacture a rubber containing article.
  • the process further comprises introducing a stream comprising hydrogen to the gas fermentation process and/or combining a stream comprising hydrogen with the raw syngas stream.
  • the first byproduct stream comprises char and the process further comprises passing the first byproduct stream to the carbon black process for conversion to carbon black.
  • the at least one material comprises a whole tire or at least a portion of a tire.
  • the downstream operation to produce an article of manufacture is at least one step of a tire production process.
  • the downstream operation to produce an article of manufacture is at least one step of a production process to manufacture a rubber containing article.
  • the at least one material is selected from coal, refinery residues, petroleum coke, biomass, lignocellulosic material, black liquor, municipal solid waste, municipal liquid waste, industrial solid waste, industrial liquid waste, refuse derived fuel, sewerage, sewerage sludge, sludge from wastewater treatment, landfill gas, biogas, tires including end of life tires, or combinations thereof.
  • Byproducts generated in the feedstock preparation for gas fermentation may be passed to the carbon black production process for the generation of additional carbon black. Secondary products generated in the carbon black process may be provided, along with the carbon black produced for use in a downstream operation to produce an article of manufacture. Secondary products generated in the carbon black process may be passed to the gas fermentation process for use in generating a gas fermentation product. Therefore, a greater amount of the initial feedstock materials are used or provided to a downstream operation for the manufacture of a new article.
  • the term “acid” as used herein includes both carboxylic acids and the associated carboxylate anion, such as the mixture of free acetic acid and acetate present in a fermentation broth as described herein.
  • the ratio of molecular acid to carboxylate in the fermentation broth is dependent upon the pH of the system.
  • acetate includes both acetate salt alone and a mixture of molecular or free acetic acid and acetate salt, such as the mixture of acetate salt and free acetic acid present in a fermentation broth as described herein.
  • substrate comprising carbon monoxide and like terms should be understood to include any substrate in which carbon monoxide is available to one or more strains of bacteria for growth and/or fermentation, for example.
  • co-substrate refers to a substance that, while not necessarily being the primary energy and material source for product synthesis, can be utilized for product synthesis when added to another substrate, such as the primary substrate.
  • underutilized gas or “underutilized gas stream” may be used to refer to any gas stream that may have greater value as a substrate to gas fermentation than a current use.
  • synthesis gas or “syngas” refers to a gaseous mixture that contains at least one carbon source, such as carbon monoxide (CO), carbon dioxide (CO 2 ), or any combination thereof, and, optionally, hydrogen (H 2 ) that can used as a feedstock for the disclosed gas fermentation processes and can be produced from a wide range of carbonaceous material, both solid and liquid.
  • carbon source such as carbon monoxide (CO), carbon dioxide (CO 2 ), or any combination thereof
  • hydrogen (H 2 ) that can used as a feedstock for the disclosed gas fermentation processes and can be produced from a wide range of carbonaceous material, both solid and liquid.
  • Processes and systems in accordance with the present disclosure can be used to transform carbon in solid and liquid feedstocks by microbial gas fermentation systems to generate valuable products and divert carbon compounds from being treated as waste and for example incinerated to create emissions into the atmosphere.
  • the primary product of gas fermentation is provided to downstream operations to produce articles of manufacture.
  • the product of gas fermentation may be provided for use as an intermediate, a reactant, a solvent, an ingredient, or other such uses in the downstream operation.
  • one or more byproducts of an integrated feedstock preparation and gas fermentation process may also be provided for use as an intermediate, a reactant, a solvent, an ingredient, or other such uses in the downstream operation.
  • Byproducts of the feedstock preparation to provide syngas to the gas fermentation may also be provided to downstream operations. The byproducts may be provided to the same downstream operation to which the gas fermentation product is provided. Further, the material provided to the feedstock preparation may be articles of the same type as being produced in the downstream operation, only that the articles used in the feedstock preparation are used, defective, or scrap articles whereas the downstream operation produces new articles.
  • both the carbon black process and the gas fermentation product may be provided to a downstream operation to produce an article of manufacture. Examples include downstream process to produce a rubber-containing article and/or tires. Additional synergies exist in the form of providing one or more secondary products from the carbon black process and/or one or more byproducts from the feedstock preparation and gas fermentation process to the downstream operation. Streams provided to the downstream operation may be provided to one or more steps of the downstream operation.
  • Gas fermentation processes that are capable of converting various carbon sources into other products are rapidly becoming a desirable alternative for producers with excess carbon. Such processes allow companies or organizations to convert standard techniques that cmit carbon into the atmosphere into a separate revenue stream by converting the waste or underutilized carbon into a marketable product. Moreover, the carbon that is converted into other products lowers the operator's total carbon output, potentially serving as a way for operators to maintain current outputs without conflicting with ever-tightening government regulations. Furthermore, tail gas from gas fermentation may be another source of CO 2 and purified to form a concentrated CO 2 stream thereby further reducing cost as compared to more traditional carbon capture and sequestration processes. The widespread adoption of gas fermentation processes could be improved by reducing the cost barriers through the use of additional material from the integrated process being available to downstream operations.
  • the substrate and/or C1 carbon source provides both the energy and the carbon source for the metabolic process of the biocatalyst, while in another embodiment, such as when CO 2 is the carbon source, depending upon the biocatalyst, a source of energy for the metabolic process is also provided.
  • the source of energy for the metabolic process may be hydrogen.
  • the hydrogen may be mixed with the C1 carbon source prior to the bioreactor of the gas fermentation system or may be independently supplied to the biorcactor.
  • the substrate and/or C1 carbon source may be in the form of a solid or liquid material which may be first processed in a preliminary step of the overall integrated gas fermentation process to generate synthesis gas known as syngas which in turn is provided to the biorcactor of the gas fermentation system.
  • the preliminary step to generate syngas may involve pyrolysis, partial oxidation, plasma, torrefaction, reforming, or gasification processes.
  • gasification processes include gasification of coal, gasification of refinery residues, gasification of petroleum coke, gasification of biomass, gasification of lignocellulosic material, gasification of waste wood, gasification of black liquor, gasification of municipal solid waste, gasification of municipal liquid waste, gasification of industrial solid waste, gasification of industrial liquid waste, gasification of refuse derived fuel, gasification of sewerage, gasification of sewerage sludge, gasification of sludge from wastewater treatment, gasification of landfill gas, gasification of biogas such as when biogas is added to enhance gasification of another material, and gasification of tires including end of life tires.
  • the microorganism of the disclosure may be cultured with the gaseous substrate to produce one or more target products.
  • Target product(s) may be selected from an alcohol, an acid, a diacid, an alkene, a terpene, an isoprene, and alkync.
  • the microorganism of the disclosure may produce or may be engineered to produce ethanol, acetate, 1-butanol, 2,3-butanediol, lactate, butene, butadiene, methyl ethyl ketone (2-butanonc), ethylene, acetonc, isopropanol, lipids, 3-hydroxypropionate (3-HP), terpenes, including isoprene, fatty acids, 2-butanol, 1,2-propanediol, 1 propanol, 1 hexanol, 1 octanol, chorismate-derived products, 3hydroxybutyrate, 1,3 butanediol, 2-hydroxyisobutyrate or 2-hydroxyisobutyric acid, isobutylene, adipic acid, 1,3 hexanediol, 3-methyl-2-butanol, 2-buten-1-ol, isovalerate, isoamyl alcohol, and/or
  • FIG. 1 which illustrates an integrated carbon black and gas fermentation (GF) system 10 with the gas fermentation having a feedstock preparation zone within the gas fermentation system.
  • FIG. 1 shows an enlarged gas fermentation process including the feedstock preparation as gasification process 102 , a gas fermentation zone 128 , a product recovery zone 144 , and an optional wastewater treatment zone 134 , along with a carbon black process 154 , and a downstream operation to produce an article of manufacture 150 .
  • Exemplary feedstock preparation gasification process 102 receives feedstock 100 , which may be any suitable material capable of being gasified to produce syngas stream 118 . Different types of feedstock preparation technique may be selected, such as pyrolysis, torrefaction, partial oxidation, and the like.
  • feedstock 100 may be comprised at least partially of sorted and/or unsorted industrial or municipal solid waste.
  • feedstock 100 may be comprised at least partially, of rubber-containing articles such as tires and end of life tires.
  • the feedstock 100 is comprised at least partially of forest and/or agricultural waste.
  • feedstock 100 is comprised of any combination of two or more of the following: sorted municipal or industrial solid waste, unsorted municipal or industrial solid waste, tires including end of life tires, rubber containing material, forest waste, agricultural waste, or other solid or liquid waste from the refining or chemical process integrated with the enlarged gas fermentation process.
  • a combination of two or more materials are processed together as one material alone may be difficult to process.
  • Possible integration internal to the enlarged fermentation process may provide for at least one effluent from the gas fermentation zone 128 , at least one effluent from the product recovery zone 144 , and/or at least one effluent from the wastewater treatment zone 134 being used as gasification fecd.
  • Gasification zone 102 produces syngas as substrate for gas fermentation zone 128 .
  • syngas 118 produced in the gasification zone 102 by the gasification process, or gas obtained from another source and combined with the syngas 118 contains one or more constituent that needs to be removed and/or converted.
  • Typical constituents found in the syngas stream 118 that may need to be removed and/or converted include, but are not limited to, sulfur compounds, aromatic compounds, alkynes, alkenes, alkanes, olefins, nitrogen compounds, phosphorous-containing compounds, particulate matter, solids, oxygen, halogenated compounds, silicon-containing compounds, carbonyls, metals, alcohols, esters, ketones, peroxides, aldehydes, ethers, and tars. These constituents may be removed by one or more removal zones 122 positioned between gasification zone 102 and gas fermentation zone 128 .
  • Removal zone 122 may comprise one or more of the following modules: hydrolysis module, acid gas removal module, deoxygenation module, catalytic hydrogenation module, particulate removal module, chloride removal module, tar removal module, and hydrogen cyanide polishing module. Two or more modules may be combined into a single module performing the same functions. The functions of all modules may be combined into a single unit with the selection of an appropriate catalyst, such as for example U.S. Pat. No. 11,441,116.
  • removal process 122 When incorporating removal process 122 , at least a portion of syngas 118 from gasification zone 102 is passed to removal process 122 to remove and/or convert at least a portion of at least one constituent found in syngas stream 118 . Removal zone 122 may operate to bring the constituent(s) within allowable levels to produce a treated stream 124 suitable for fermentation by in gas fermentation zone 128 .
  • Fermentation process 128 employs at least one C1-fixing microorganism in a liquid nutrient media to ferment a feedstock gas, or syngas stream 124 and produce one or more products.
  • the C1-fixing microorganism in fermentation process 128 may be a carboxydotrophic bacterium, or an acetogenic carboxydotrophic bacterium.
  • the C1-fixing microorganism may be an acetogenic carboxydotrophic bacterium.
  • the C1-fixing microorganism may be selected from the group comprising Moorella, Clostridium, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, Methanosarcina, Cupriavidus and Desulfotomaculum .
  • the acetogenic carboxydotrophic bacterium is Clostridium autoethanogenum.
  • the one or more products produced in fermentation zone 128 are removed and/or separated from the fermentation broth in product recovery zone 144 .
  • Product recovery zone 144 separates and removes one or more product(s) 132 and produces at least one effluent 142 , 130 , 112 , which comprise reduced amounts of at least one product.
  • Product depleted effluent may be sent via a conduit 142 to wastewater treatment zone 134 to produce at least one effluent 136 , which may be recycled to the gasification process 102 and/or the fermentation process 128 .
  • an effluent from fermentation zone 128 is tail gas containing gas generated by the fermentation, inert gas, and/or unmetabolized substrate. At least a portion of this tail gas may be passed via a conduit 114 to gasification zone 102 to be used as part of feedstock 100 . At least a portion of the tail gas may be sent via conduit 114 and a conduit 116 to syngas 118 , an effluent of gasification zone 102 , to quench syngas stream 118 . At least a portion of the tail gas may be passed outside of the enlarged gas fermentation process.
  • At least a portion of a wastewater stream, comprising fermentation broth, which may contain microbial biomass from fermentation zone 128 may be passed to optional gasification zone 102 , without being passed to product recovery zone 144 .
  • Downstream operation 150 has feedstock 162 to produce articles 152 . Both gas fermentation product stream 132 and carbon black product stream 156 are provided to downstream operation 150 . One or more secondary products 156 from carbon back process 154 and one or more byproducts 148 may be provided to downstream operation 150 .
  • Downstream operation is a process to produce an article of manufacture. Various different processes are suitable, and of particular interest are processes to produce an article comprising rubber. Many rubber containing products utilize carbon black and at least one step of the production process involves the addition of carbon black to the process. Another particularly advantageous downstream operation is the production of tires. Tires also utilize carbon back to enhance the performance of the tires.
  • the products of gas fermentation can be catalytically converted, for example, by catalytic process unit. Additionally or alternatively, the products of gas fermentation can be catalytically converted, for example, by catalytically upgrading, into molecules, or one or more second products, wherein the one or more second products are provided to steps of a process to manufacture an article.
  • molecules produced via the catalysis of the products of gas fermentation processes may also be considered desirable products or further products of fermentation.
  • a further embodiment comprises converting the ethanol generated by the method into ethylene. This can be accomplished by way of an acid catalyzed dehydration of ethanol to give ethylene according to the following formula: CH 3 CH 2 OH ⁇ CH 2 ⁇ CH 2 +H 2 O
  • ethylene generated in this way may be used for a variety of applications on its own or can be used as a raw material for more refined chemical products.
  • ethylene alone may be used as an anesthetic, as part of a mixture with nitrogen to control ripening of fruit, as a fertilizer, as an element in the production of safety glass, as part of an oxy-fuel gas in metal cutting, welding and high velocity thermal spraying, and as a refrigerant.
  • ethylene can used in the manufacture of polymers such as polyethylene (PE), polyethylene terephthalate (PET) and polyvinyl chloride (PVC) as well as fibres and other organic chemicals.
  • PE polyethylene
  • PET polyethylene terephthalate
  • PVC polyvinyl chloride
  • Ethylene can be chlorinated to ethylene dichloride (EDC) and can then be cracked to make vinyl chloride monomer (VCM). Nearly all VCM is used to make polyvinyl chloride which has its main applications in the construction industry.
  • EDC ethylene dichloride
  • VCM vinyl chloride monomer
  • ethylene derivatives include alpha olefins which are used in Linear low-density polyethylene (LLDPE) production, detergent alcohols and plasticizer alcohols; vinyl acetate monomer (VAM) which is used in adhesives, paints, paper coatings and barrier resins; and industrial ethanol which is used as a solvent or in the manufacture of chemical intermediates such as ethyl acetate and ethyl acrylate.
  • LLDPE Linear low-density polyethylene
  • VAM vinyl acetate monomer
  • industrial ethanol which is used as a solvent or in the manufacture of chemical intermediates such as ethyl acetate and ethyl acrylate.
  • Ethylene may further be used as a monomer base for the production of various polyethylene oligomers by way of coordination polymerization using metal chloride or metal oxide catalysts.
  • the most common catalysts consist of titanium (III) chloride, the so-called Ziegler-Natta catalysts.
  • Another common catalyst is the Phillips catalyst, prepared by depositing chromium (VI) oxide on silica.
  • Polyethylene oligomers so produced may be classified according to its density and branching. Further, mechanical properties depend significantly on variables such as the extent and type of branching, the crystal structure, and the molecular weight.
  • polyethylene which may be generated from ethylene, including, but not limited to:
  • Low density polyethylene (LDPE) and linear low-density polyethylene (LLDPE) mainly go into film applications such as food and non-food packaging, shrink and stretch film, and non-packaging uses.
  • High density polyethylene (HDPE) is used primarily in blow molding and injection molding applications such as containers, drums, household goods, caps and pallets. HDPE can also be extruded into pipes for water, gas and irrigation, and film for refuse sacks, carrier bags and industrial lining.
  • the ethylene formed from the ethanol described above may be converted to ethylene oxide via direct oxidation according to the following formula: C 2 H 4 +O 2 ⁇ C 2 H 4 O
  • ethylene oxide produced thereby is a key chemical intermediate in a number of commercially important processes including the manufacture of monocthylene glycol.
  • Other EO derivatives include ethoxylates (for use in shampoo, kitchen cleaners, etc.), glycol ethers (solvents, fuels, etc.) and ethanolamines (surfactants, personal care products, etc.).
  • the monocthylene glycol can be the subject of an esterification reaction utilizing terephthalic acid according to the following reaction: n C 6 H 4 (CO 2 H) 2 +n HOCH 2 CH 2 OH ⁇ [(CO)C 6 H 4 (CO 2 CH 2 CH 2 O)] n +2 n H 2 O
  • the polyethylene terephthalate produced according to either the transesterification or esterification of monoethylene glycol has significant applicability to numerous packaging applications such as jars and, in particular, in the production of bottles, including plastic bottles. It can also be used in the production of high-strength textile fibers such as Dacron, as part of durable-press blends with other fibers such as rayon, wool, and cotton, for fiber fillings used in insulated clothing, furniture, and pillows, in artificial silk, as carpet fiber, automobile tire yarns, conveyor belts and drive belts, reinforcement for fire and garden hoses, seat belts, nonwoven fabrics for stabilizing drainage ditches, culverts, and railroad beds, and nonwovens for use as diaper topsheets, and disposable medical garments.
  • high-strength textile fibers such as Dacron
  • other fibers such as rayon, wool, and cotton
  • PET can be made into a high-strength plastic that can be shaped by all the common methods employed with other thermoplastics. Magnetic recording tape and photographic film are produced by extrusion of PET film. Molten PET can be blow-molded into transparent containers of high strength and rigidity that are also virtually impermeable to gas and liquid. In this form, PET has become widely used in bottles, especially plastic bottles, and in jars.
  • isopropanol or isopropyl alcohol (IPA) produced according to the method may be used in numerous product applications, including either in isolation or as a feedstock for the production for more complex products.
  • Isopropanol may also be used in solvents for cosmetics and personal care products, de-icers, paints and resins, food, inks, adhesives, and pharmaceuticals, including products such as medicinal tablets as well as disinfectants, sterilizers, and skin creams.
  • silica containing sludge may be produced in gasification with particular types of gasifiers.
  • the silica may be recovered from the sludge and provided to a downstream operation to produce an article of manufacture. Both the fermentation product and the recovered silica may be provided to the same downstream operation to produce an article of manufacture, to the same or different steps within the operation.
  • the downstream operation may be to produce rubber containing articles, such as, for example, tires.
  • Yet another byproduct of the feedstock preparation may be a metal or metal oxide.
  • Such metal or metal oxide may be produced in gasification with particular types of gasifiers.
  • the metal or metal oxide may be recovered from the gasifier and provided to a downstream operation to produce an article of manufacture. Both the fermentation product and the recovered silica may be provided to the same downstream operation to produce an article of manufacture, to the same or different steps within the operation.
  • the downstream operation may be to produce rubber containing articles, such as, for example, tires.
  • the metal may be zinc and the metal oxide maybe zinc oxide. Since zinc and/or zinc oxide is particularly apt to be present when the at least one material gasified in the gasifier is a tire or portions of tires, it is most advantageous when the downstream operation is to produce new tires.
  • Yet another byproduct of the feedstock preparation may be a steel.
  • Such steel may be recovered from gasification with particular types of pretreatment techniques such as, for example, pyrolysis.
  • the steel may be recovered from the pretreatment unit and provided to a downstream operation to produce an article of manufacture. Both the fermentation product and the recovered steel may be provided to the same downstream operation to produce an article of manufacture, to the same or different steps within the operation.
  • the downstream operation may be to produce rubber containing articles, such as, for example, tires. When the downstream operation is to produce tires, the steel is particularly valuable. Since steel is particularly apt to be present when the at least one material processed in the feedstock pretreatment, such as pyrolysis, is a whole tire or portions of a tire with the steel components not removed, it is most advantageous when the downstream operation is to produce new tires.
  • One or more byproducts of the feedstock preparation may be produced and recovered.
  • One or more of the byproducts produced and recovered may be provided to the downstream operation or to the carbon black process.
  • Two or more byproducts of the feedstock preparation may be produced and recovered and provided to the same downstream operation.
  • the two or more byproducts may be provided to the same or different steps of the downstream operation.
  • Three or more byproducts of the feedstock preparation may be produced and recovered and provided to the same downstream operation.
  • the three or more byproducts may be provided to the same or different steps of the downstream operation.
  • Four or more byproducts of the feedstock preparation may be produced and recovered and provided to the same downstream operation.
  • the four or more byproducts may be provided to the same or different steps of the downstream operation.
  • the byproducts of the feedstock preparation may be produced and recovered and provided to the same downstream operation to which the gas fermentation product is provided.
  • the carbon black process produces secondary products that may be passed to the gas fermentation process or provided to the downstream operation.
  • most types of carbon black processes produce carbon dioxide as a secondary product which may be passed to the gas fermentation process.
  • Some types of carbon black processes produce hydrogen as a secondary process which may also be passed to the gas fermentation process.
  • some types of carbon black processes generate secondary product of sulfur and/or sulfur containing components.
  • Such sulfur and/or sulfur containing components may be separated from the carbon dioxide secondary product, the hydrogen secondary product, or both. Additionally or alternatively, such sulfur and/or sulfur containing components may be recovered from a step of the carbon black process.
  • the secondary product of sulfur and/or sulfur containing components may be provided to the downstream operation.
  • downstream operation When the downstream operation is directed to a process for producing a rubber containing article or a tire, it is advantageous to provide the secondary product of sulfur and/or sulfur containing components to at least one step of the downstream operation.
  • Sulfur recovery techniques are well known and not discussed here in detail. Suitable examples include oxidative desulfurization and Claus-type processes.
  • unutilized carbon dioxide which may be in the form of an off gas from the gas fermentation, may be a secondary product used within the gas fermentation process.
  • unutilized carbon dioxide will be in a stoichiometrically higher proportion in the off gas compared to the feedstock, and this relative purity can make the carbon dioxide useful.
  • the unutilized carbon can be sequestered by an operator for the purposes of obtaining carbon credits, or it may be combined with hydrogen gas (H 2 ), such as “green hydrogen” resulting from electrolysis, and recycled back into the gas fermenter or bioreactor as feedstock.
  • H 2 hydrogen gas
  • the disclosed systems and methods integrate microbial fermentation into existing or newly built infrastructure of, for example, a gas (e.g., natural gas) transportation pipeline, oil well, or the like to convert various feedstocks, gas, or other by-products into useful products such as ethylene.
  • a gas e.g., natural gas
  • the systems allow for feedstocks, gas, or other by-products to be directly provided to a bioreactor, and the bioreactor is directly connected to a system for facilitating transport of a desirable product of fermentation to an end point (e.g., a chemical plant or refinery).
  • the disclosed systems and methods are applicable for producing useful products (e.g., ethylene, ethanol, acetate, etc.) from gascous substrates, such as gases that may optionally contain H 2 , that are utilized as a carbon source by microbial cultures.
  • gascous substrates such as gases that may optionally contain H 2 , that are utilized as a carbon source by microbial cultures.
  • microorganisms may include bacteria, archaca, algae, or fungi (e.g., yeast), and these classes of microorganism may be suitable for the disclosed systems and methods.
  • the selection of the microorganism(s) is not particularly limited so long as the microorganism is C1-fixing, carboxydotrophic, acetogenic, methanogenic, capable of Wood-Ljungdahl synthesis, a hydrogen oxidizer, autotrophic, chemolithoautotrophic, or any combination thereof.
  • bacteria are particularly well suited for integration in the disclosed systems and methods.
  • the bacteria may be aerobic or anaerobic, depending on the nature of the carbon source and other inputs being fed into the bioreactor or fermentation unit.
  • the bacteria utilized in the disclosed systems and methods can include one of more strains of carboxydotrophic bacteria.
  • the carboxydotrophic bacterium can be selected from a genus including, but not limited to, Cupriavidus, Clostridium, Moorella, Carboxydothermus, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, Methanosarcina , and Desulfotomaculum .
  • the carboxydotrophic bacterium is Clostridium autoethanogenum .
  • the carboxydotrophic bacterium is Cupriavidus necator.
  • a number of anaerobic bacteria are known to be capable of carrying out fermentation for the disclosed methods and system.
  • bacteria that are suitable for use in the invention include bacteria of the genus Clostridium , such as strains of Clostridium ljungdahlii (including those described in WO 00/68407, EP 117309, U.S. Pat. Nos. 5,173,429, 5,593,886, and 6,368,819, WO 98/00558 and WO 02/08438), Clostridium carboxydivorans (Liou et al., International Journal of Systematic and Evolutionary Microbiology 33: U.S. Plant Pat. No.
  • Clostridium autoethanogenum Clostridium autoethanogenum (Abrini et al., Archives of Microbiology 161: pp 345-351).
  • Other suitable bacteria include those of the genus Moorella , including Moorella sp HUC22-1(Sakai et al., Biotechnology Letters 29: U.S. Plant Pat. No. 1,607-1612), and those of the genus Carboxydothermus (Svetlichny, V. A., et al. (1991), Systematic and Applied Microbiology 14:254-260). The disclosures of each of these publications are incorporated herein by reference.
  • carboxydotrophic anaerobic bacteria can be used in the disclosed systems and methods by a person of skill in the art. It will also be appreciated upon consideration of the instant disclosure that a mixed culture of two or more bacteria may be used in the disclosed systems and methods. All of the foregoing patents, patent applications, and non-patent literature are incorporated herein by reference in their entirety.
  • Clostridium autoethanogenum is a Clostridium autoethanogenum having the identifying characteristics of the strain deposited at the German Resource Centre for Biological Material (DSMZ) under the identifying deposit number 19630.
  • the Clostridium autoethanogenum is a Clostridium autoethanogenum having the identifying characteristics of DSMZ deposit number DSMZ 10061.
  • the Clostridium autoethanogenum is a Clostridium autoethanogenum having the identifying characteristics of DSMZ deposit number DSMZ 23693.
  • the anaerobic bacteria is Clostridium carboxidivorans having the identifying characteristics of deposit number DSM15243. In some embodiments, the anaerobic bacteria is Clostridium drakei having the identifying characteristics of deposit number DSM12750. In some embodiments, the anaerobic bacteria is Clostridium ljungdahlii having the identifying characteristics of deposit number DSM13528. Other suitable Clostridium ljungdahlii strains may include those described in WO 00/68407, EP 117309, U.S. Pat. Nos.
  • the anaerobic bacteria is Clostridium scatologenes having the identifying characteristics of deposit number DSM757. In some embodiments, the anaerobic bacteria is Clostridium ragsdalei having the identifying characteristics of deposit number ATCC BAA-622.
  • the anaerobic bacteria is Acetobacterium woodii . In some embodiments, the anaerobic bacteria is from the genus Moorella , such as Moorella sp HUC22-1, (Sakai et al, Biotechnology Letters, 29: pp. 1,607-1612).
  • the fermentation may be carried out in any suitable bioreactor.
  • the bioreactor may comprise a first, growth reactor in which the microorganisms (e.g., bacteria) are cultured, and a second, fermentation reactor, to which fermentation broth from the growth reactor is fed and in which most of the fermentation product (e.g. ethylene, ethanol, acetate, etc.) is produced.
  • the microorganisms e.g., bacteria
  • the fermentation product e.g. ethylene, ethanol, acetate, etc.
  • temperature of the culture may vary as needed.
  • the fermentation is carried out at a temperature of about 34° C. to about 37° C.
  • the fermentation is carried out at a temperature of about 34° C.
  • This temperature range may assist in supporting or increasing the efficiency of fermentation including, for example, maintaining or increasing the growth rate of bacteria, extending the period of growth of bacteria, maintaining or increasing production of the desired product (e.g., ethylene, ethanol, acetate, etc.), or maintaining or increasing CO or CO 2 uptake or consumption.
  • fermentation is carried out in any suitable bioreactor, such as a continuous stirred tank reactor, a bubble column reactor, or a trickle bed reactor.
  • the bioreactor may comprise a first, growth reactor in which the micro-organisms are cultured, and a second, fermentation reactor, to which fermentation broth from the growth reactor is fed and in which most of the fermentation product (e.g., ethylene, ethanol, acetate, etc.) is produced.
  • valve or metering mechanism can be useful for a variety of purposes including, but not limited to, slugging of product through a connected pipeline and measuring the amount of output from a given bioreactor such that if the product is mixed with other gases or liquids the resulting mixture can later be mass balanced to determine the percentage of the product that was produced from the biorcactor.
  • a portion of the substrate and/or C1-carbon source may be a gas stream comprising methane.
  • a methane containing gas may be obtained from: fossil methane emissions such as during fracking, wastewater treatment, livestock, agriculture, and municipal solid waste landfills. It is also envisioned that the methane may be burned to produce electricity or heat and the C1 by-products may be used as the substrate or carbon source.
  • the substrate and/or C1-carbon source may be a gas stream comprising natural gas.
  • Embodiment 6 The process of any of embodiments 1 to 5 wherein the first secondary product stream comprises carbon dioxide, hydrogen, or both.
  • Embodiment 10 The process of any of embodiment 1 to 9 wherein the first secondary product stream further comprises sulfur or a sulfur containing component, the process further comprising separating a first sulfur or a sulfur containing component stream from the first secondary product stream and providing the first sulfur or a sulfur containing component stream to the downstream operation.
  • Embodiment 13 The process of any of embodiments 1 to 12 wherein the hydrogen of the stream comprising hydrogen may be green hydrogen, blue hydrogen, grey hydrogen, pink hydrogen, turquoise hydrogen, yellow hydrogen, and/or white hydrogen.
  • Embodiment 14 The process of any of embodiments 1 to 13 further comprising introducing a stream comprising hydrogen to the gas fermentation process and/or combining a stream comprising hydrogen with the raw syngas stream and wherein the hydrogen of the stream comprising hydrogen may be green hydrogen, blue hydrogen, grey hydrogen, pink hydrogen, turquoise hydrogen, yellow hydrogen, and/or white hydrogen.
  • Embodiment 16 The process of any of embodiments 1 to 15 wherein the first byproduct stream comprises char and the process further comprises passing the first byproduct stream to the carbon black process for conversion to carbon black.
  • Embodiment 17 The process of any of embodiments 1 to 16 wherein the at least one material comprises a whole tire or at least a portion of a tire.
  • Embodiment 18 The process of any of embodiment 1 to 17 wherein the tire is an end of life tire.
  • Embodiment 19 The process of any of embodiments 1 to 18 wherein the at least one material comprises a whole tire or at least a portion of a tire, and/or a whole end of life time or a portion of an end of life tire.
  • Embodiment 20 The process of any of embodiments 1 to 19 wherein the downstream operation to produce an article of manufacture is at least one step of a tire production process.
  • Embodiment 21 The process of any of embodiments 1 to 20 wherein two or more byproduct streams are produced by the partial oxidation, pyrolysis, torrefaction, reforming, or gasification process and the two or more byproduct streams are provided to the same or different steps of a production process to manufacture a tire.
  • Embodiment 22 The process of and of embodiments 1 to 21 wherein the at least one material comprises a natural or synthetic rubber containing material.
  • Embodiment 24 The process of any of embodiments 1 to 23 wherein two or more byproduct streams are produced by the partial oxidation, pyrolysis, torrefaction, reforming, or gasification process and the two or more byproduct streams are provided to the same or different steps of the production process to manufacture a rubber containing article.
  • Embodiment 25 The process of any of embodiments 1 to 24 wherein the at least a portion of the carbon black stream and the at least a portion of the at least one fermentation product are provided to the same or different steps of the downstream operation.
  • Embodiment 26 The process of any of embodiments 1 to 25 wherein the downstream operation is a process for the production of tires.
  • Embodiment 29 The process of any of embodiments 1 to 28 wherein the microorganism is selected from a genus of Clostridium, Moorella, Carboxydothermus, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, Methanosarcina, Desulfotomaculum , and Cupriavidus.
  • any concentration range, percentage range, ratio range, integer range, size range, or thickness range is to be understood to include the value of any integer within the recited range and, when appropriate, fractions thereof (such as one tenth and one hundredth of an integer), unless otherwise indicated.

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